Tampon and method of making

ABSTRACT

A tampon has a pair of longitudinally extending side edges and an absorbent member. The absorbent member has an insertion area, a withdrawal area, and an intermediate area between the insertion area and the withdrawal area and an attachment area. The absorbent material has a plurality of fiber integrated nonwoven layers but are without fiber integration adjacent layers outboard of the attachment area. A withdrawal line extends from the withdrawal area and is attached to the absorbent member in the attachment area such that each of the plurality of absorbent layers is attached to an adjacent nonwoven layer in the attachment area.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of, and claims priority under 35U.S.C. § 120 to, U.S. patent application Ser. No. 16/684,640, filed Nov.15, 2019, which is a continuation of U.S. patent application Ser. No.14/801,871, filed on Jul. 17, 2015, now issued as U.S. Pat. No.10,568,777, on Feb. 25, 2020, which claims the benefit, under 35 USC §119(e), of U.S. Provisional Patent Application Ser. No. 62/026,092 filedon Jul. 18, 2014, the entireties of which are fully incorporated byreference herein.

FIELD OF THE INVENTION

This invention relates to absorbent articles such as tampons. Inparticular, this invention relates to an improved catamenial tampon.

BACKGROUND OF THE INVENTION

A wide variety of absorbent catamenial tampons have long been known inthe art. While it has been found that these tampons perform theirintended function tolerably well, even the best of them do not alwaysre-expand sufficiently, or fast enough, to provide good coverage againstleakage. This failure to re-expand can lead to “bypass” failure whichoccurs when the menses travels along the length of the vagina withoutcontacting the tampon, i.e., the tampon fails to intercept the flowingmenses.

For ease of application, tampons are typically compressed to facilitateinsertion into the vaginal cavity. While tampons can generally becompressed to a small diameter to accomplish facilitation duringinsertion, too much compression can inhibit the tampon's ability tore-expand once inserted into the vaginal cavity.

Accordingly, there is a need for a tampon with improved performancewhile maintaining or improving comfort during insertion to the wearer.

SUMMARY OF THE INVENTION

Tampons of the present invention may provide benefits to the consumer asprovided herein. In some embodiments, a tampon comprises an absorbentmember comprising an insertion area, a withdrawal area, and anintermediate area between the insertion area and the withdrawal area.The absorbent member further comprises an attachment area and absorbentmaterial. The absorbent material comprises a plurality of fiberintegrated nonwoven layers and are without fiber integration betweenadjacent fiber integrated nonwoven layers outboard of the attachmentarea.

A withdrawal line extends from the withdrawal area and is attached tothe absorbent member in the attachment area. And, each of the pluralityof absorbent layers are attached to an adjacent nonwoven layer in theattachment area.

A method of producing a tampon comprising the steps of (1) providing aplurality of fiber integrated nonwoven layers each having a basis weightof greater than about 75 grams per square meter; (2) stacking each ofthe plurality of fiber integrated nonwoven layers; (3) providing awithdrawal line; and (4) attaching the withdrawal line to the pluralityof fiber integrated nonwoven layers in an attachment area such that eachof the plurality of fiber integrated nonwoven layers is attached to anadjacent fiber integrated nonwoven layer in the attachment area.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter of the present invention, itis believed that the invention can be more readily understood from thefollowing description taken in connection with the accompanyingdrawings, in which:

FIG. 1 is a plan view showing a tampon (in an unfolded state)constructed in accordance with the present invention.

FIG. 2 is a cross-sectional view of the tampon of FIG. 1 taken alongline 2-2.

FIG. 3 is a cross-sectional view of a tampon showing another embodimentof the present invention.

FIGS. 4A-4C are cross-sectional views of tampons constructed inaccordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The following text sets forth a broad description of numerous differentembodiments of the present invention. The description is to be construedas exemplary only and does not describe every possible embodiment sincedescribing every possible embodiment would be impractical, if notimpossible. And it will be understood that any feature, characteristic,component, composition, ingredient, product, step or methodologydescribed herein can be deleted, combined with or substituted for, inwhole or part, any other feature, characteristic, component,composition, ingredient, product, step or methodology described herein.Numerous alternative embodiments could be implemented, using eithercurrent technology or technology developed after the filing date of thispatent, which would still fall within the scope of the claims. Allpublications and patents cited herein are incorporated herein byreference.

It should also be understood that, unless a term is expressly defined inthis specification using the sentence “As used herein, the term ‘ ’ ishereby defined to mean . . . ” or a similar sentence, there is no intentto limit the meaning of that term, either expressly or by implication,beyond its plain or ordinary meaning, and such term should not beinterpreted to be limited in scope based on any statement made in anysection of this patent (other than the language of the claims). No termis intended to be essential to the present invention unless so stated.To the extent that any term recited in the claims at the end of thispatent is referred to in this patent in a manner consistent with asingle meaning, that is done for sake of clarity only so as to notconfuse the reader, and it is not intended that such a claim term belimited, by implication or otherwise, to that single meaning. Finally,unless a claim element is defined by reciting the word “means” and afunction without the recital of any structure, it is not intended thatthe scope of any claim element be interpreted based on the applicationof 35 U.S.C. § 112(f).

As used herein, “cm” is centimeter, “mm” is millimeters, “ml” ismilliliters “g” is grams, “gsm” is grams per square meter, “sec” isseconds.

As used herein “fiber integration” refers to the entanglement of fibersvia mechanical processing or hydroentanglement. “Fiber integrated” shallrefer to nonwoven materials which have been subjected to mechanicalprocessing or hydroentangling. The mechanical processes orhydroentangling drive Z-direction integration of the fibers.

As used herein “hydrophilic” and “hydrophobic” have meanings as wellestablished in the art with respect to the contact angle of a drop ofwater on the surface of a material. Thus, a material having a contactangle of greater than about 75 degrees is considered hydrophobic, and amaterial having a contact angle of less than about 75 degrees isconsidered hydrophilic. Absolute values of hydrophobicity/hydrophilicityare not generally important, but relative values are.

As used herein, the term “tampon” refers to any type of absorbentstructure that can be inserted into the vaginal cavity or other bodycavity, such as, e.g., for the absorption of fluid, to aid in woundhealing, and/or for the delivery of materials, such as moisture oractive materials such as medicaments.

As used herein the terms “vaginal cavity,” “within the vagina” and“vaginal interior,” are intended to be synonymous and refer to theinternal genitalia of the human female in the pudendal region of thebody. The term “vaginal cavity” as used herein is intended to refer tothe space located between the introitus of the vagina (sometimesreferred to as the sphincter of the vagina) and the cervix and is notintended to include the interlabial space, including the floor ofvestibule. The externally visible genitalia generally is not includedwithin the term “vaginal cavity” as used herein.

The present invention relates to a tampon comprising an absorbentmaterial which can improve performance and may, in some embodiments,improve comfort for the wearer. For ease of reference, as shown in FIGS.1 through 3 , for tampons constructed in accordance with the presentinvention, a longitudinal direction 1500 shall refer to a directionextending generally parallel to the maximum length of the tampon in thecompressed state. And, a z-direction 1000 shall refer to a directionextending generally perpendicular to the longitudinal direction 1500 andis associated with the thickness of the tampon. A lateral direction 1750is generally parallel to a width of the tampon as measured betweenopposite longitudinal edges of the tampon.

Referring to FIG. 1 , a tampon 100, constructed in accordance with oneembodiment of the present invention, is depicted in an expanded state.The longitudinal axis 1010 is generally parallel to the longitudinaldirection 1500. The longitudinal axis 1010 may bisect a width of thetampon 100 as measured from a first longitudinal edge 1010A to a secondlongitudinal edge 1010B.

The tampon 100 comprises an absorbent member 160 and a withdrawal line150. The absorbent member 160 has an insertion area 110, a withdrawalarea 120, and an intermediate area 130. The intermediate area 130 isdisposed between the insertion area 110 and the withdrawal area 120 andconnects the insertion area 110 and the withdrawal area 120. Theinsertion area 110, withdrawal area 120 and intermediate area 130 mayeach make up about a third of the length of the absorbent member 160 insome forms. However, in other forms, the withdrawal area 120 may make upless than 20 percent of the length of the absorbent member 160, lessthan 15 percent of the length of the absorbent member 160, or less thanabout 10 percent of the length of the absorbent member 160.

The absorbent member 160 further comprises an attachment area 140. Thewithdrawal line 150 is attached to the absorbent member 160 in theattachment area 140. The withdrawal line 150 is attached to theabsorbent member 160 and graspable by the user for removal of the tampon100 after use. The withdrawal line 150 may be attached to at least theabsorbent member 160 and extends beyond the withdrawal area 120. Asshown, in some embodiments, the attachment area 140 may be generallyco-linear with the longitudinal axis 1010. However, embodiments arecontemplated where the attachment area 140 is generally parallel to thelongitudinal axis 1010 but laterally offset therefrom. In additionalembodiments, the attachment area 140 may be linearly and/or angularlydisplaced with respect to the longitudinal axis 1010.

As shown, the attachment area 140 may extend from the insertion area 110to the withdrawal area 120. Embodiments are contemplated where theattachment area 140 is limited to the insertion area 110 and/or thewithdrawal area 120. Additionally, embodiments are contemplated wherethe attachment area 140 is limited to the intermediate area 130 and/orthe insertion area 110 or the withdrawal area 120.

With regard to FIG. 2 , the absorbent member 160 comprises absorbentmaterial 170 which comprises a plurality of fiber integrated nonwovenlayers. As shown, in some embodiments, the absorbent material 170 maycomprise six fiber integrated nonwoven layers, 570, 580, 590, 600, 610,and 620. Referring to FIG. 3 , in some embodiments, the absorbentmaterial 170 may comprise seven fiber integrated nonwoven layers, 570,580, 590, 600, 610, 620 and 630. In some embodiments, the absorbentmaterial 170 may comprise additional fiber integrated nonwoven layers.For example, embodiments are contemplated where the absorbent material170 comprises greater than 7 layers, greater than 8 layers, greater than9 layers, greater than 10 layers, greater than 11 layers, greater than12 layers, greater than 13 layers, greater than 14 layers, greater than15 layers, greater than 16 layers, greater than 17 layers, greater than18 layers, greater than 19 layers, and/or less than 20 layers, less than19 layers, less than 18 layers, less than 17 layers, less than 16layers, less than 15 layers, less than 14 layers, less than 13 layers,less than 12 layers, less than 11 layers, less than 10 layers, less than9 layers, or less than 8 layers. Additionally, embodiments arecontemplated where the number of layers is less than 6. For example, insome embodiments, the absorbent material 170 may comprise 5 layers, lessthan 4 layers, less than 3 layers, or 2 layers.

In some embodiments, each of the plurality of fiber integrated nonwovenlayers is homogeneous and each comprises homogenous fibers. For example,each fiber integrated nonwoven layers may comprise 100 percent viscoserayon. However, embodiments, are contemplated where each of theplurality of fiber integrated nonwoven layers comprises a blend ofcotton and rayon. As an example, each of the plurality of fiberintegrated nonwoven layers may comprise about 20 percent cotton andabout 80 percent rayon, about 30 percent cotton and about 70 percentrayon, about 40 percent cotton and about 60 percent rayon, or about 50percent cotton and about 50 percent rayon. Additional examples includeabout 20 percent rayon and about 80 percent cotton, about 30 percentrayon and about 70 percent cotton, or about 40 percent rayon and about60 percent cotton. Other percentages encompassed by the values statedabove as well as other ranges encompassed by the values stated above arecontemplated.

Additional embodiments are contemplated where each of the plurality offiber integrated nonwoven layers of absorbent material 170 comprise apercentage of plastic fiber. For example, each of the plurality of fiberintegrated nonwoven layers of absorbent material 170 may compriseplastic fibers selected from at least one of polypropylene,polyethylene, polyethylene teraphthalate, poly lactic acid, and thelike. For those embodiments where the fiber integrated nonwoven layerscomprise plastic fiber, each of the plurality of fiber integratednonwoven layers of absorbent material 170 may comprise about 1 percentto about 50 percent of plastic fibers, from about 5 to about 25 percent,or from about 10 to about 20 percent. The addition of plastic fibers mayaid the transfer/movement of menses from one area to another of theabsorbent material 170.

In one exemplary embodiment, each of the plurality of fiber integratednonwoven layers may have a basis weight of about 100 grams per squaremeter (“gsm”). In some embodiments, each of the plurality of fiberintegrated nonwoven layers may be at a basis weight of greater thanabout 20 gsm, greater than about 30 gsm, greater than about 40 gsm,greater than about 50 gsm, greater than about 60 gsm, greater than about70 gsm, greater than about 75 gsm, greater than about 80 gsm, greaterthan about 85 gsm, greater than about 90 gsm, greater than about 95 gsm,greater than about 100 gsm, greater than about 110 gsm, greater thanabout 120 gsm, greater than about 130 gsm, greater than about 140 gsm,greater than about 150 gsm, greater than about 160 gsm, greater thanabout 170 gsm, greater than about 180 gsm, greater than about 190 gsm,or less than about 200 gsm or any ranges encompassed by these valuesand/or any number within these values.

In some embodiments, the cumulative basis weight of the absorbentmaterial 170 may be between about 200 gsm and 1200 gsm. In someembodiments, the cumulative basis weight of the absorbent material 170may be greater than about 200 gsm, greater than about 300 gsm, greaterthan about 400 gsm, greater than about 500 gsm, greater than about 600gsm, greater than about 700 gsm, greater than about 800 gsm, greaterthan about 900 gsm, greater than about 1000 gsm, greater than about 1100gsm, or less than or equal to about 1200 gsm. Embodiments arecontemplated wherein the cumulative basis weight of the absorbentmaterial 170 comprises a range encompassed by the values above and/orwherein the cumulative basis weight of the absorbent material 170 is anumber within the values provided above.

As stated previously, the absorbent material 170 comprises a pluralityof fiber integrated nonwoven layers. In some embodiments, each fiberintegrated nonwoven layer may be created via hydroentangling. In otherembodiments, each of the plurality of fiber integrated nonwoven layersmay be created via mechanical processing. A suitable example ofmechanical processing is needlepunching. As another example, the fiberintegrated nonwoven layers may each comprise a spunlace nonwoven.Spunlace nonwoven materials may be carded and subsequentlyhydroentangled. As each of the layers is hydroentangled or in someembodiments needlepunched, each layer is individually fiber integratedprior to becoming a constituent of the absorbent material 170.

As shown, the attachment area 140 provides strength and integrity to thetampon 100 by attaching each of the fiber integrated nonwoven layers toadjacent fiber integrated nonwoven layers. In some embodiments, thefiber integrated nonwoven layers may be sewn together in the attachmentarea 140 such that the fiber integrated nonwoven layers are fiberintegrated in the attachment area 140. Within each fiber integratednonwoven layer, strength and integrity is provided via fiber integrationand Z-direction fiber entanglement. However, between the fiberintegrated nonwoven layers, excepting the attachment area 140, no fiberintegration is provided. And as shown, the attachment area 140 isdisposed laterally inboard of the longitudinal edges 1040A and 1040B.Accordingly, no fiber integration is present outboard of the attachmentarea 140 between the fiber integrated nonwoven layers.

The absorbent member 160 is compressed and placed into an insertiondevice prior to use. During compression, fibers of one fiber integratednonwoven layer may intermingle with fibers of adjacent fiber integratednonwoven layers to some extent. However, conventional compressionpressures should not be sufficient to detract from the performance ofthe absorbent material 170. Accordingly, fiber integration does notinclude fiber intermingling which is created from compressing theabsorbent material 170 and/or calendar bonding the absorbent material170.

The fiber integrated nonwoven layers may be attached to one another inthe attachment area 140 by any suitable method. As an example and asstated previously, the fiber integrated nonwoven layers may be attachedto one another in the attachment area 140 by being sewn together. Whensewn together, thread is integrated into each of the fiber integratednonwoven layers attaching each of the fiber integrated nonwoven layerstogether. In contrast, constituent fibers of each of the fiberintegrated nonwoven layers are integrated within only their respectivelayers.

Without wishing to be bound by theory, it is believed that because thelayers of nonwoven material are provided with fiber integration betweenadjacent layers only in the attachment area 140, the layers of nonwovenmaterial expand more freely and more easily than absorbent material ofconventional tampons. In order to provide integrity to the absorbentmaterial of conventional tampons, many provide fiber integration acrossthe entire thickness of the absorbent material and across the entirewidth of the tampon, i.e. fiber integration between adjacent layers. Theconventional use of fiber integration of the absorbent material isbelieved to inhibit the expansion and movement of the absorbentmaterial. Alternatively, some may provide structural integrity to layersof absorbent material via fusion bonding. Such bonding is believed toinhibit the movement/expansion of the absorbent material which canresult in reduced performance.

In contrast, and as stated previously, the fiber integration providedfor each nonwoven layer provides structural integrity of each of theindividual nonwoven layers. And, the attachment area 140 providesstructural integrity to the absorbent member 160. Because each of thefiber integrated layers comprise no fiber integration outboard of theattachment area 140 and because each of the fiber integrated layers areattached in the attachment area 140, it is believed that theexpansion/movement of each of the fiber integrated nonwoven layers isless inhibited than absorbent material of conventional tampons.

As shown in FIGS. 2 and 3 , a width 145 of the attachment area 140 doesnot extend a full width 275 or 375 of a tampon constructed in accordancewith the present invention. In some embodiments, the width 145 of theattachment area 140 may be about 3 mm or about 8 mm. In someembodiments, the width 145 of the attachment area can be less than about25 mm, less than about 20 mm, less than about 15 mm, less than about 10mm, less than about 5 mm, or less than about 3 mm, or greater than orequal to about 1 mm. Embodiments are contemplated where the width 145 iswithin a range encompassed by the values above or is a number that isencompassed by the values above.

In another embodiment, the width 145 of the attachment area 140 mayvary. As an example, the width 145 of the attachment area 140 adjacentthe insertion area 110 (shown in FIG. 1 ) may be different than thewidth 145 of the attachment area 140 adjacent the withdrawal area 120(shown in FIG. 1 ). As an example, adjacent the insertion area 110, thewidth 145 of the attachment area 140 may be less than the width 145 ofthe attachment area 140 adjacent the withdrawal area 120. In anotherembodiment, the width 145 of the attachment area 140 adjacent theinsertion area 110 may be greater than the width 145 of the withdrawalarea 120. In still other embodiments, the width 145 of the attachmentarea 140 may be different in the intermediate area 130 (shown in FIG. 1) than the width 145 of the attachment area 140 of either the insertionarea 110 and/or the withdrawal area 120. Embodiments are contemplatedwhere the width 145 of the attachment area 140 is varied in combinationwith the positioning of the attachment area 140 as discussed previously.

The width 275 or 375 of the tampon in an unrolled and/or unfolded statecan be from about 30 mm to about 120 mm or about 50 mm to about 70 mm,including all numbers within these ranges and any ranges formed thereby,in some embodiments. In some embodiments, the attachment area 140 may bedisposed greater than about 20 mm laterally inboard of the longitudinaledges 1040A/1040B. In some embodiments, the attachment area 140 may bedisposed greater than about 25 mm laterally inboard, 30 mm laterallyinboard, or 35 mm laterally inboard of the longitudinal edges 1040A and1040B.

Surprisingly, the inventors have found that when the absorbent material170 comprises layers, where each layer is 100 gsm spunlace nonwovenmaterial, with 100% viscose rayon fibers, the cross sectional areas (ina compressed state) of the absorbent member 160 can be less than that ofconventional tampons. Table 1 shows a comparison of the compressed crosssectional areas of a currently marketed tampon versus the compressedcross sectional area of tampons constructed in accordance with FIGS. 2and 3 . The compressed cross sectional area was taken after beingremoved from the applicator and within a few minutes of being removedfrom the applicator.

TABLE 1 Compressed Cross Diameter Sectional Area % Area ProductDescription (mm) (square mm) Reduction Currently marketed - 14.93 175.070% Tampax Pearl Super 100 gsm, 100% viscose 14.56 166.50 5% rayon - 6layers 100 gsm, 100% viscose 14.49 164.90 6% rayon - 7 layers

The smaller cross sectional areas are believed to provide more comfortduring insertion of the tampon. Additionally, from a macro viewpoint,the smaller cross sectional areas could reduce applicator size. Thereduction of applicator size could in turn reduce the cost as well asthe amount of packaging utilized for individual tampons. This could inturn result in a reduction in the amount of packaging for the tampon boxcomprising a plurality of tampons and for the box comprising a pluralityof tampon boxes, etc.

Additionally, even with the smaller—prior to use—cross sectional area,the experimental tampons performed well with regard to the FDA syngynaspecification.

TABLE 2 Dry tampon Product Description Syngyna (g) weight (g) Currentlymarketed - 11.3 2.84 Tampax Pearl Super 6 layers each of 100 gsm, 10.782.47 100% viscose rayon 7 layers each of 100 gsm, 11.87 2.80 100%viscose rayon

As shown in Table 2, the seven layer embodiments of 100 gsm spunlace,100% viscose rayon, performed better on the syngyna test than did theconventional tampons tested. The syngyna method is disclosed hereafter.The efficiency of the 6 layer and 7 layer experimental products was 4.36g syngyna/g of fiber and 4.23 grams sygyna/grams of fiber, respectively.In contrast, the conventional efficiency was 3.98 g of syngyna/g offiber.

Another benefit of the absorbent material 170 of the present inventionis that regardless of the configuration, e.g. 6 layers or 7 layers, eachhas a dry weight less than that of a comparable conventional tampon.

As shown in FIG. 4A, forms of the present invention are contemplatedwhere the plurality of fiber integrated layers comprises a singlenonwoven web 4000. For example, the first layer 570, second layer 580,third layer 590, fourth layer 600, fifth layer 610, and sixth layer 620may each be part of the same nonwoven web. As shown, the nonwoven web4000 may be folded a plurality of times to form each of these layers.Additional forms are contemplated where a plurality of nonwoven webs areutilized and folded at least once to form a plurality of layers.Examples are provided in FIGS. 4B and 4C.

As shown in FIG. 4B, a plurality of nonwoven webs, 4000, 4010, 4020 maybe utilized to form the plurality of layers. As shown, in some forms ofthe present invention, three nonwoven webs may be utilized where eachmay form at least two layers. Other forms are contemplated. For example,two nonwoven webs 4000 and 4010 may be utilized where each of thenonwoven webs may form at least three layers.

Additionally, it is believed that the loft of the individual layers canimpact the performance of the absorbent material 160. It is believedthat recovery after compression for those layers with lower loft may beinhibited. In contrast, for those layers with greater loft prior tocompression would experience better recovery in use. Loft of theindividual layers can be greater than about 0.95 mm, greater than about1.0 mm, greater than about 1.1 mm, greater than about 1.2 mm, greaterthan about 1.3 mm, greater than about 1.4 mm, or greater than about 1.5mm, specifically including all values within these ranges and any rangescreated thereby.

Tampons of the present invention may be processed in a variety ofmanners. In one embodiment, the absorbent material 170 may be acquiredby a supplier such as Sandler AG. Alternatively, the absorbent materialmay be manufactured from fibers. In general fiber processing requiresobtaining a bale of fibers suitable for use as the absorbent material170. As stated previously, fibers may include cotton, rayon, plastic, orcombinations thereof. In one embodiments, a bale cutter breaks apart thefibers and provides the fibers to a fiber carding machine or turbocarding machine. The fiber carding machine cards the fibers. Note thatan unbonded carded nonwoven web typically has little to no strength inthe CD or z-direction. In order to achieve the desired basis weight, aplurality of unbonded carded nonwoven web may be combined into a singlenonwoven web. The unbonded carded nonwoven web(s) may be provided to ahydroentangling device or a needlepunch device, each of which are knownin the art. Other manufacturing processes which can entangle fibers ofthe carded webs may also be utilized. As stated previously, viahydroentangling or needlepunching, the carded nonwoven web(s) arecombined via fiber entanglement which provides strength to resultant webthereby creating a nonwoven web. This process may be repeated aplurality of times to produce the desired number of fiber integratednonwoven layers in the absorbent material 170. The nonwoven materials ofthe present invention may be turbo carded.

Carding of nonwovens typically orients fibers in a desired direction.Typically the fiber orientation is in the machine direction. Subsequentmechanical processing, e.g. hydroentangling or needlepunching, providesZ-direction integration of the fibers and does not substantially changethe initial fiber orientation.

Forms of the present invention are contemplated where fiber orientationis substantially in the cross machine direction. By “substantially” itis meant that when viewed under microscope, a majority of fibers of asample nonwoven, e.g. sample absorbent material of a tampon in question,would be oriented in the cross machine direction (perpendicular to thewalls of the applicator in which the absorbent was housed). Other formsare contemplated where the fiber orientation is substantially in themachine direction.

As stated above, the nonwoven material for the fiber integrated nonwovenlayers may be purchased and provided on a roll to a converting line orproduced internally and provided to the converting line. The providednonwoven material may be cut and layers of the provided nonwovenmaterial are stacked to form the absorbent material 170. The withdrawalline 150 (shown in FIG. 1 ) is provided to the converting line. Thewithdrawal line 150 is attached to the absorbent material 170 which canalso attach adjacent fiber integrated nonwoven layers in the attachmentarea 140. Alternatively, the fiber integrated nonwoven layers may befiber integrated and/or attached separate from the attachment of thewithdrawal line. 150.

As an optional step, prior to and/or after attaching the withdrawal line150, the plurality of layers of nonwoven material may be calendared toensure that appropriate thickness prior to packaging. The calendar rollsmay be heated to provide light bonding between the fiber integratednonwoven layers within and/or external to the attachment area 140. Suchlight bonding is believed to be relatively weak and provide little to norestriction in the movement/expansion of the fiber integrated nonwovenlayers with respect to one another. Such light bonding is not consideredto be fiber integration.

Subsequently, the absorbent material 170 comprising the plurality offiber integrated nonwoven layers may be compressed and pushed into anapplicator. Much like calendaring, the compression of the plurality offiber integrated nonwoven layers may create light bonding betweenadjacent fiber integrated nonwoven layers; however, such light bonds arebelieved to be relatively weak and provide little to no restriction inthe movement/expansion of the fiber integrated nonwoven layers. Again,such light bonding is not considered to be fiber integration.

Pressures and temperatures suitable for compression are well known inthe art. Typically, the absorbent material and the fluid perviousoverwrap are compressed in the radial direction and optionally axiallyby any means well known in the art. While a variety of techniques areknown and acceptable for these purposes, a tampon compressor machineavailable from Hauni Machines, Richmond, Va., is suitable.

Referring to FIGS. 1-4C, in some embodiments, the absorbent material 170may be surrounded, at least in part, by an overwrap. For thoseembodiments, with an overwrap, the overwrap may surround at least theintermediate area 130 of the absorbent material 170 and may in someembodiments, cover the insertion area 110 and/or the withdrawal area120. In some embodiments, the overwrap may extend beyond the withdrawalarea 120 and create a skirt around the absorbent material 170.

In some embodiments, the overwrap may be attached to the absorbentmaterial 170 in the attachment area 140 and unattached everywhere else.In some embodiments, the overwrap may be attached to the absorbentmaterial 170 in the attachment area 140 and may be attached to theabsorbent material 170 via fusion bonds. In such embodiments, theoverwrap may comprise fibers with a lower melting temperature than thatof the absorbent material 170. So the fusion bonds are only created withregard to the overwrap and not the absorbent material 170.

For those embodiments including overwraps, the overwrap may comprise amasking region and a wicking region. In other embodiments two separateoverwraps (a masking overwrap which becomes a masking region and awicking overwrap which becomes wicking region) may be provided to formthe final overwrap (which may or may not be joined). Whether it is amasking region or a “separate” masking overwrap, the masking materialmay be hydrophobic or may be treated to render the region or overwraphydrophobic if the starting if material is hydrophilic. Treatments thatrender a material hydrophobic include but are not limited to applying toor dipping the material in silicones, fatty acids (such as sucrose esterfatty esters), fluorocarbons, such as SCOTCHGUARD, and waxes. Whether itis a wicking region or a wicking overwrap, the wicking material may behydrophilic or may treated to render the region or overwrap to behydrophilic if the starting material is hydrophobic. Treatments thatrender a material hydrophilic include but are not limited to applying ordipping the material in surfactants, including non-ionic surfactants.

In other embodiments where two pieces of material are used to form theoverwrap, a masking material/region/overwrap may be joined to a wickingmaterial/region/overwrap by sewing, adhesives, bonding includingthermally bonding, pressure fusion bonding, or any other suitable meansknown in the art for joining such materials. Alternatively, the twomaterials used to create the overwrap may not be physically connected atall.

In some embodiments, the absorbent member 160 may be compressed prior toapplication of the overwrap onto the absorbent member 160. In suchembodiments, the overwrap may be positioned on the compressed absorbentmember such that the wicking region/overwrap covers at least a portionof the exterior surface of the compressed absorbent member proximal tothe withdrawal end and the masking region/overwrap surrounds at least aportion of the exterior surface of the compressed absorbent memberproximal to the insertion end. In some embodiments, the wickingregion/overwrap extends beyond the withdrawal end of the compressedabsorbent member to define a skirt portion. In embodiments that beginwith providing a compressed absorbent member, the overwrap, comprisingboth the wicking region/overwrap and the masking region/overwrap, may bejoined or applied to the compressed absorbent member subsequent tocompression. Alternatively, a wicking overwrap may be applied prior tocompression (discussed further below) and a masking overwrap may beapplied subsequent to compression. Overwraps applied subsequent tocompression should be extensible such that the tampon will be able toexpand within the vagina. The overwrap may be made extensible byprocesses such as, ring rolling, creping, MICREXing, and SELFing asdescribed in U.S. Pat. No. 5,518,801 issued to Chappell on May 21, 1996,incorporated herein by reference.

The optional overwrap material is liquid permeable via natural liquidpathways or aperturing. Exemplary overwrap materials include non-wovenscomprising a blend of synthetic and natural fibers, and polymeric films.The synthetic fibers may include, but are not limited to, fibers such aspolyester, polyolefin, nylon, polypropylene, polyethylene, polyacrylic,cellulose acetate, or bicomponent fibers. Natural fibers may include,but are not limited to, those commonly known to be non-synthetic and ofnatural origin such as cotton and/or rayon. Polymeric films can comprisepolyolefins and polyesters, for example. Depending on their intendeduse, the polymeric films may be made liquid permeable through aperturingor other “opening” technique.

The withdrawal line 150 of the present invention could be joined to theabsorbent member 160 and graspable by the user for removal after use.Any of the withdrawal lines currently known in the art, such as string,may be used as a suitable withdrawal mechanism. In addition, thewithdrawal lines can take on other forms such as a ribbon, loop, tab, orthe like. The withdrawal line may be integral with the absorbentmaterial. In some embodiments, the withdrawal line may be discrete andnon-integral with the absorbent material or optional overwrap.

The withdrawal line may be attached in any suitable manner known in theart including sewing, adhesive attachment, or a combination of knownbonding methods. The withdrawal line may be joined to any suitablelocation on the tampon.

The withdrawal line material and configuration can vary. A fibrousstring is an exemplary embodiment of the withdrawal line. The withdrawalline can comprise any suitable synthetic material, natural material, orblends thereof. Suitable synthetic materials include, for example,non-natural material, such as, for example, polyethylene, polypropylene,polyethylene-polypropylene copolymer, polyvinyl alcohol, polyvinylacetate, polyester, nylon, polylactides, polyhydroxylalkanoates,aliphatic ester polycondensates, cellulose acetate, and mixturesthereof. Such fibers can be formed in any suitable manner, such as,e.g., by melt spinning to produce staple fibers, monofilaments,multifilaments, continuous filaments, or other fibers useful in forminga withdrawal string. Fiber formation and processing generally includesthe addition of finish compositions, such as, for example, lubricantsand anti-statics.

The withdrawal line can be any suitable construction. For example, incertain embodiments, the withdrawal line can be a twisted or knittedconstruction containing multiple plies of yarn. The plies of yarn can beformed from twisted staple fibers or multiple continuous filaments. Inaddition, or alternatively, the weight or count of the yarn and/or thenumber of plies can be any weight or plies suitable for providing thedesired strength, aesthetics, grippability, wearing comfort, handling,cost, and/or processing. In certain embodiments, the withdrawal line canbe formed from 6 twisted plies of 10 count polypropylene yarn, oneknitted ply of 10 count polypropylene yarns, or any other suitableconstruction

The withdrawal line fibers can have any suitable cross-sectional shape,such as, e.g., round, tri-lobal, multi-lobal, delta, hollow,ribbon-shaped, and/or any other suitable shape, or mixtures thereof.Fibers with any suitable diameter can be used, such as, e.g., from about0.5 to about 50 microns, such as, e.g., from about 1 to about 30microns, such as, e.g., from about 10 to about 25 microns. Fiberdiameter can be determined using any suitable means; however, fornon-round fibers, diameter can typically be determined by reference tothe diameter of a fiber with the same cross-sectional area as thenon-round fiber.

Test Methods Syngyna Test

The Syngyna test is carried out as described in 21 CFR § 801.430(f)(2).

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a dimension disclosed as “40 mm” is intended to mean“about 40 mm.”

Every document cited herein, including any cross referenced or relatedpatent or application, is hereby incorporated herein by reference in itsentirety unless expressly excluded or otherwise limited. The citation ofany document is not an admission that it is prior art with respect toany invention disclosed or claimed herein or that it alone, or in anycombination with any other reference or references, teaches, suggests ordiscloses any such invention. Further, to the extent that any meaning ordefinition of a term in this document conflicts with any meaning ordefinition of the same term in a document incorporated by reference, themeaning or definition assigned to that term in this document shallgovern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

What is claimed is:
 1. A tampon comprising an absorbent member,comprising: an insertion area, a withdrawal area, an intermediate areabetween the insertion area and the withdrawal area, and an attachmentarea; the absorbent member comprising a plurality of discrete nonwovenlayers in a stacked and layered configuration; wherein each of thestacked nonwoven layers extends along a plane along a longitudinaldirection parallel with a longitudinal axis of the absorbent member, anda lateral direction perpendicular to the longitudinal direction; andwherein the nonwoven layers are stacked along a z-directionperpendicular to the plane, and wherein the stacked nonwoven layers areattached together in the attachment area to form a unitary stackincluding all of the layers, such that two or more of the nonwovenlayers are attached within an adjacent nonwoven layer via a withdrawalline joining to the absorbent member in the attachment area, and notfiber integrated to an adjacent nonwoven layer in areas outboard of theattachment area; and wherein the withdrawal line extends from thewithdrawal area and comprises a string, ribbon, loop, or tab.
 2. Thetampon of claim 1, wherein the withdrawal line is discrete andnon-integral with each of the nonwoven layers.
 3. The tampon of claim 1,wherein each of the nonwoven layers comprises a hydroentangled spunlacenonwoven.
 4. The tampon of claim 1, wherein each of the nonwoven layerscomprises a hydroentangled nonwoven having a basis weight of greaterthan 75 grams per square meter.
 5. The tampon of claim 1, wherein theabsorbent member comprises from between 2 nonwoven layers and 20nonwoven layers, and wherein each of the nonwoven layers has a basisweight of 30 between about 20 grams per square meter to about 600 gramsper square meter.
 6. The tampon of claim 1, wherein the absorbent membercomprises from between 4 nonwoven layers and 8 nonwoven layers, andwherein each of the nonwoven layers have a basis weight of between about30 grams per square meter to about 250 grams per square meter.
 7. Thetampon of claim 1, wherein the absorbent member comprises at least 7nonwoven layers and wherein each of the nonwoven layers comprise a basisweight of between about 75 grams per square meter to about 120 grams persquare meter.
 8. The tampon of claim 1, wherein each of the nonwovenlayers is needlepunched and has a basis weight of greater than 75 gramsper square meter.
 9. The tampon of claim 1, wherein each of the nonwovenlayers comprises a blend of cotton and rayon fibers.
 10. The tampon ofclaim 1, wherein each of the nonwoven layers comprises plastic fibers.11. The tampon of claim 1, wherein each of the nonwoven layers comprisesplastic fibers selected from the group consisting of polypropylenefibers, polyethylene fibers, polyethylene terephthalate fibers,polylactic acid fibers, and combinations thereof.
 12. The tampon ofclaim 1, wherein each of the nonwoven layers has a basis weight ofbetween about 75 grams per square meter to about 120 grams per squaremeter.
 13. The tampon of claim 1, further comprising an overwrap whichsurrounds at least the intermediate area.
 14. The tampon of claim 1,wherein at least two or more of the nonwoven layers are fiber integratedin the attachment area.